Atmospheric Plasma Spraying Method Research Articles

Wear energy approach for evaluation of tribological properties of Cr2O3-TiO2 coating

Abstract In the present work, Cr2O3-TiO2 ceramic coating was deposited by atmospheric plasma spray (APS) method. Tribological response of coating was thoroughly examined using two different sizes of SiC abrasives under four distinct loads. Coatings were characterized by Scanning Electron Microscopy, Energy Dispersive Spectroscopy, X-Ray Diffraction, Raman spectroscopy and X-Ray Photoelectron Spectroscopy. The coating experienced 31–40% lower friction coefficient at coarser particle size whereas 1.4–1.6 times lower wear rates were obtained at finer particle size. Results were explained on the basis of adhesion-abrasion components of friction. Consequences of formation of a tribo-oxide film and its implications on specific energy for material removal along with wear mechanisms are also discussed. A modified wear energy parameter (WEP) is used and showed good correlation with experimentally measured wear rates and friction coefficient of the coating.

A Comparison of the Tribological Properties of SiC Coatings Prepared via Atmospheric Plasma Spraying and Chemical Vapor Deposition for Carbon/Carbon Composites

The microstructure, mechanical performance, and tribological properties of SiC ceramic coatings prepared via atmospheric plasma spraying (APS) and chemical vapor deposition (CVD) method were compared to provide good anti-wear protection for carbon/carbon composites. The surface morphology of the APS-SiC coating was characterized as having a porous structure, whilst the CVD-SiC coating presented with many pyramidal-shaped crystals constituting the surface. The APS-SiC coating consists of a dominating SiC phase and a small fraction of the Si phase, while the XRD pattern of the CVD-SiC coating mainly consists of the SiC phase. The dense crystalline microstructure of the CVD-SiC coating made it possess a higher hardness and Young’s modulus at 31.0 GPa and 275 GPa, respectively. The higher H/E and H3/E2 parameters of the CVD-SiC coating implied that it exhibited better plastic resistance, which is also beneficial for anti-wear properties. The scratch test reflected the critical loads of the spallation of the APS-SiC coating and CVD-SiC coating, which were evaluated to be 25.9 N and 36.4 N, respectively. In the tribological test, the friction coefficient of the APS-SiC coating showed obvious fluctuations at high load due to damage to the SiC coating. The wear mechanism of the APS-SiC coating was dominated by abrasive wear and fatigue wear, while CVD-SiC was mainly dominated by abrasive wear. The wear rate of the CVD-SiC coating was far below that of the APS-SiC coating, suggesting the better wear-resistance of the CVD-SiC coating.

Investigation of wear behaviour of TiO2 and Al2O3 reinforced YSZ coating

In this study, three different ceramic powders used as thermal barriers were coated on AISI304 stainless steel by the atmospheric plasma spray method. A pin-on-disc apparatus was utilised to investigate the wear characteristics of the coatings. The effect of wear behavior of the addition of Al2O3 and titanium dioxide (TiO2) into the YSZ coating was investigated. Before the wear test, sanding and polishing processes were carried out to ensure that the average surface roughness of the coatings was less than 0.8 µm. The wear test according to ASTM G99-04, was conducted on a pin-on-disc device at a speed of 143 rpm. The test was performed in a dry condition, with a minimum of 8000 cycles. The wear test utilised a 4N load and 6 mm-diameter Al2O3 balls. The surface properties and wear characteristics of the coatings were analysed using a scanning electron microscope (SEM) and energy-dispersive X-ray spectroscopy (EDS) after conducting coating and wear tests. The wear rate of the samples was assessed using optical profilometry. A micro Vickers test equipment was employed to assess the microhardness of the materials. The findings demonstrated that the inclusion of Al2O3 in YSZ led to an enhancement in wear resistance, but the incorporation of TiO2 resulted in a notable reduction in wear resistance.

Usage of Thermal Coatings for the Improvement of Material Properties for Ballistic Protection in the Military Field. A Review

Abstract In this review, the impact on the ballistic protection properties for some materials used in the military field was analysed, in relation to the improvement of mechanical and microstructural properties. The main objective was the ballistic protection materials with the potential to be used as ballistic protection for applications such as bulletproof vests. In the addition to the evaluation related to improvement of the considered material proprieties, the impact on the improvement of the ballistic protection grades was also evaluated in relation with the test standards such as: NIJ, VPAM, NATO STANAG 4569 (Association of Test Laboratories for Attack Resistant Materials and Constructions, 2024; NATO Standardization Office NSDD, 2022; NIJ, 2023). The evaluation that is subject of this paper, it consists of two types of processes: thermal coating using Atmospheric Plasma Spray (APS) method and coatings using Cold Spray method. Using these methods of improving the mechanical properties, the impact on ballistic protection grades was highlighted, considering both standards:(NIJ) Standard 0101.07 (NIJ, 2023) and NIJ Standard 0123.00 (NIJ, 2023), which are defined in alignment with National Institute of Justice from USA. The impact of the materials was also evaluated in relation to the standard VPAM “Association of Test Laboratories for Attack Resistant Materials and Constructions” (Association of Test Laboratories for Attack Resistant Materials and Constructions, 2024) with intended use in Europe and also standard “NATOStandardization Agreements” AEP-55 STANAG 4569 (NATO Standardization Office NSDD, 2022).

Investigation of Yb2SiO5/BSAS/Si coating on Cf/SiC composites: processing and steam corrosion behavior

Environmental Barrier Coatings (EBCs) are used to protect silicon carbide-based composites in the high-temperature steam combustion environment of the latest generation of high-efficiency gas turbine aero-engines. The Yb2SiO5/BSAS/Si coatings with gradient coefficient of thermal expansion were prepared using atmospheric plasma spraying (APS) method on the carbon fiber reinforced silicon carbide ceramic matrix composites (Cf/SiC) composites surface. The coating preparation process parameters were optimized by evaluating the influence of spraying power on the bonding strength, deposition efficiency, and porosity. The corrosion behaviors and mechanism of the optimized Yb2SiO5/BSAS/Si coating was investigated at 1200 ℃ by thermal cycle test in steam conditions. The results indicated that the decomposition of Yb2SiO5 and the conversion of SiO2 to Si(OH)4 were the main corrosion reactions of Yb2SiO5 top coating. Noticeably, the SiO2 component acted as an obvious sign of the reaction front diffusing, forming the clear SiO2-gradient layers. The gradient Yb2SiO5/BSAS/Si coating remained intact after thermal cycles for 500 h at 1200 ℃ in steam conditions which effectively enhanced the resistance of Cf/SiC composites to high temperature steam corrosion.

Influence of Spray Angle on Particle Deposition and Thermal Shock Lifetime of Embedded Micro-Agglomerated Particle Coatings

The development of gas turbine technology has led to an increase in the complexity of the geometric shape of the sprayed workpiece. Consequently, it has become more difficult to maintain the perpendicularity of the spraying angle during the spraying process, thereby impacting the structure and performance of the coating. This study uses the atmospheric plasma spraying method to simultaneously spray two types of powder for the preparation of embedded micro-agglomerated particle (EMAP) coatings. The spraying process is conducted at four different angles, ranging from 90° to 30°, in order to analyze the influence of the spray angle on the particle deposition and coating performance. The experimental results demonstrate that the relative deposition efficiency, hardness, and elastic modulus of the EMAP coatings decreased as the spray angle decreased. The porosity exhibited a reduction when the spraying angle dropped from 90° to 50°, followed by a significant rise at 30°. The greatest relative amount of second phase particles embedded in the coating appeared at a spraying angle of 90°, amounting to 10.8%. The smallest amount was found at a spraying angle of 30°, with a relative quantity of 2.2%. Furthermore, the molten droplets of the first phase matrix powder underwent extension and fragmentation along the angular direction at low angles. At an angle of 90°, the maximum average thermal shock life was 40.6 cycles, with the best stability of thermal shock life. The decrease in the spraying angle resulted in a deterioration in both the thermal shock life and its stability.

High-Temperature Oxidation Resistance and Molten Salt Corrosion Study of YSZ, CeYSZ, and YSZ/CeYSZ Thermal Barrier Coatings by Atmospheric Plasma Spraying

Five thermal barrier coatings (TBCs), namely TBC-1 (YSZ), TBC-2 (CeYSZ), TBC-3 (YSZ:CeYSZ = 1:2), TBC-4 (YSZ:CeYSZ = 1:1), and TBC-5 (YSZ:CeYSZ = 2:1), were fabricated using the atmospheric plasma spraying (APS) method. Their oxidation behaviors at 1100 °C and corrosion resistance to molten salts (V2O5 + Na2SO4) at 900 °C were examined. After 100 h of oxidation, the thermally grown oxide layer (TGO) for YSZ primarily contained Cr and Ni oxides with significant internal fractures, presenting a continuous band-like Al2O3. In dual-ceramic configurations, an increase in CeYSZ thickness led to a rise in Al content and reduced Cr and Ni in TGO, with the surface fracture morphing into an internal porosity. Following salt corrosion, YSZ revealed rod-like YVO4 and m-ZrO2 as corrosion products, whereas CeYSZ displayed chain-structured CeO2, CeYO4, and YVO4 combined with m-ZrO2. YSZ coatings underwent notable phase transitions with evident densification, forming a corrosion layer of approximately 10 μm. Conversely, CeYSZ showed a limited phase change, retaining porosity without a distinguishable corrosion layer. As CeYSZ thickness increased from 100 μm to 200 μm in the dual-ceramic structure, salt penetration reduced. Evidently, the dense structure of CeYSZ heightened diffusion resistance against oxygen and corrosive salts, rendering superior oxidation and corrosion resistance over YSZ. By optimizing the thickness ratio between CeYSZ and YSZ, whilst retaining total ceramic layer thickness, the dual-ceramic TBC’s resistance to high-temperature oxidation and corrosion can be enhanced.

Long-Cycle Stability of In Situ Ultraviolet Curable Organic/Inorganic Composite Electrolyte for Solid-State Batteries.

Lithium-ion solid-state batteries with spinel Li4Ti5O12 (LTO) electrodes have significant advantages, such as stability, long life, and good multiplication performance. In this work, the LTO electrode was obtained by the atmospheric plasma spraying method, and a composite solid electrolyte was prepared by in situ ultraviolet (UV) curing on the LTO electrode. The composite solid electrolyte was designed using a soft-hard combination strategy, and the electrolyte was prepared into a composite of a poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) flexible structure and high-conductivity Li1.3Al0.3Ti1.7(PO4)3 (LATP) hard particles. The composite electrolyte exhibited a good ionic conductivity up to 0.35 mS cm-1 at 30 °C and an electrochemical window above 4.0 V. In situ and ex situ electrolytes were assembled into LTO//electrolyte//Li solid-state batteries to investigate their impact on the electrochemical performance of the batteries. As a result, the assembled Li4Ti5O12//in situ electrolytes//Li batteries exhibited excellent rate of performance, and their capacity retention rate was 90% at 0.2 mA/cm2 after 300 cycles. This work provides a new method for the fabrication of novel advanced solid-state electrolytes and electrodes for applications in solid-state batteries.

Effect of aluminum content on plasma resistance and contamination particle generation in yttrium aluminum oxide coatings

Yttrium aluminum oxide (YAO) has garnered interest due to its ability to protect the interior parts of process chambers from the corrosive effects of fluorine-based plasma. This ability is attributed to its low melting point, which enhances the internal bonding capabilities of the atmospheric plasma spray (APS) method. We explored the resistance of YAO coatings, with varying yttrium-to-aluminum content ratios, to fluorine-based plasma. These coatings were applied using the APS method and subsequently subjected to NF3/O2 gas. Our results revealed that a higher Al content ratio resulted in a decreased number of defects within the coating, which also led to selective etching at the initial Al2O3-rich sites, primarily creating relatively weak Al-F bonds and smaller particles. In particular, selecting an appropriate yttrium-to-aluminum content ratio significantly reduced the coating defects and enhanced the etch rate compared to coatings with a higher yttrium content ratio. This improvement was attributed to the balanced presence of Al-F and Y-F bonds. Furthermore, for coatings rich with the yttrium aluminum garnet (YAG) phase, the resistance to fluorine-based plasma was primarily influenced by the thickness of the APS-Y2O3 layer. This layer, used to augment adhesion to parts, relies on the low-temperature crystallization features of YAG. The findings of this study offer valuable insights for optimizing YAG coating in dry-etching processes requiring high-density APS coatings.

Optical Properties of Spherical YAG:Ce<sup>3+</sup> Phosphor Powders Synthesized by Atmospheric Plasma Spraying Method Appling PVA Solution Route and Domestic Aluminium Oxide Seed

Optical Properties of Spherical YAG:Ce<sup>3+</sup> Phosphor Powders Synthesized by Atmospheric Plasma Spraying Method Appling PVA Solution Route and Domestic Aluminium Oxide Seed

Atmospheric plasma spray coating of antibacterial nano silver-hydroxyapatite on titanium surface for biomedical applications

ABSTRACT In this paper, the nanosilver particles were deposited onto the hydroxyapatite (HAP) microparticles and the obtained nanoAg-HAP particles were coated onto the Ti metal surface using the atmospheric plasma spray method. Then, the obtained nanoAg-HAP coating on Ti substrate was annealed at 700°C. The antibacterial activities of the nanoAg-HAP coatings on Ti were also tested against the microorganisms. The prepared nanoAg-HAP particles were examined using the optic microscopy, FE-SEM, HR-TEM, XRD and the UV-vis. absorption spectroscopy methods. The nanoAg particles exhibited crystalline spherical morphologies with the particle sizes below 30 nm. In the FE-SEM-EDS measurements, well distribution of nanoAg particles on the HAP microparticles were observed with Ag concentrations of 0.153% and 0.313%. The HR-TEM measurements showed that the nanoAg particles have hexagonal close packing (hcp) crystal structure with the d-spacing values of 0.23 nm (111), 0.21 nm (002) and 0.14 nm (022). After 700°C heat treatment, the prepared nanoAg-HAP coating on Ti metal showed 100% antibacterial activity against E. coli and S. epidermidis bacteria. As a result, the obtained nanoAg-HAP coated Ti metal can be utilized effectively as a self-disinfecting biomedical implant material in the orthopedic bone repairing of the body parts.

Preparation and Study of Ca/Tb Co-Doped HfO2 Infrared Coatings with Different Atomic Ratios

In this study, HfO2 coatings co-doped with different Ca/Tb atomic ratios were prepared via the atmospheric plasma spraying (APS) method. The microstructure, infrared radiation properties, and high-temperature stability of the coatings were investigated. All of the doped coatings possessed a porous surface and were composed of two phases, namely the monoclinic HfO2 phase and the cubic HfO2 phase. In addition, the content of the cubic phases increased when raising the doping atomic ratio of Ca/Tb, suggesting that Ca could stabilize the cubic HfO2 phase more effectively. The results also show that the coating with a Ca/Tb atomic ratio of 1/0 (CT1 coating) had more excellent infrared radiative properties, whose total emissivity was 0.844 in the 0.75~6.5 μm band and 0.900 in the 6.5~15 μm band, respectively. The improvement in emissivity in the 0.75~6.5 μm band was mainly due to the impurity energy levels introduced via oxygen vacancy, which promoted the absorption of free carriers. And, in 6.5~15 μm, because the approximate masses of the Ca-O and Tb-O bonds were smaller than that of the Hf-O bonds, the infrared absorption of the lattice vibration shifted, favoring absorption below 10 μm. Moreover, Ca had a more significant strengthening effect than Tb in the whole band. In terms of high-temperature infrared radiation performance, the total emissivity of the CT1 coating at 2.5~25 μm increased as the temperature increased from 500 °C to 1100 °C, which might be attributed to the thermal-enhanced lattice vibration absorption. However, the emissivity of the CT1 coating at 3~5 μm was kept around 0.9 from 1100 °C to 2000 °C, owing to the fact that infrared absorption was more determined by the intrinsic width of the energy levels because of the weakening of the doping effect at high temperatures. In terms of thermal stability, the surface morphology and chemical composition of the CT1 coating were barely changed within 4 h of heat treatment at 2000 °C. The total infrared emissivity of the CT1 coating after 4 h of heat treatment was 0.826 in the 0.75~6.5 μm band and 0.895 in the 6.5~15 μm band, slightly lower than that before heat treatment, suggesting good thermal stability and good application prospects as a high-temperature infrared material.

Effects of Thermal Barrier Coated Piston on Performance and Combustion Characteristics in Dual-Fuel Common-Rail Diesel Engine

In this study, performance and combustion characteristics of biogas and biogas+hydrogen mixtures were experimentally analysed and compared with baseline diesel fuel in a common-rail diesel engine with and without thermal barrier coated piston. Tests were conducted at three different loads (50 Nm, 75 Nm, and 100 Nm) and a constant speed of 1750 min-1. Engine pistons were coated with Yttria Stabilized Zirconia by atmospheric plasma spray method. Results showed that by replacing the standard pistons with the coated pistons, an increase for diesel, biogas, and hydrogen enriched biogas was respectively defined by 8.1%, 6%, and 23% in cylinder pressure, and 19.8%, 12.6%, and 25% in HRR at medium load. Similarly, there was an increase in range of 1.05-12.8% in gas temperature and 20.5-117.2% in knock intensity by the piston coating. CA10-90 was prolonged between 1-15 oCA with gaseous fuel modes and increased with the engine load. Volumetric efficiency was reduced by 0.1-4% with the gaseous fuel operations, while it was increased by using the coated piston for all fuels. Exhaust gas temperature increased with the gaseous fuels whereas showed discrepancies with the coated piston engine. Dual-fuel mode and coated pis-ton application caused brake specific energy consumption to increase significantly.

Coating of a lignin-based polymer with ceramic micropowders

This paper examines the behavior of Arboblend V2 Nature biopolymer samples coated with three distinct ceramic powders: Amdry 6420 (Cr2O3), Metco 143 (ZrO2 18TiO2 10Y2O3), and Metco 136F (Cr2O3-xSiO2-yTiO2). Atmospheric Plasma Spray (APS) method were used to deposit the coating onto the polymeric substrate, which was obtained by injection molding. Several characteristics of the coated samples, as thermal behavior, roughness, as well as structural and morphological aspects, were evaluated during the investigation. The surface analysis of the samples demonstrated a uniform deposition for the ZrO2 18TiO3 10Y2O3 layer, but a less uniform deposition for the coatings containing ceramic micro-particles of chromium (III) oxides. The thermal research revealed the material's structural resilience. Regarding Atomic Force Microscopy examination, it highlighted the roughness of the coated surfaces and also the good adhesion of the microparticles on the biopolymer substrate.

Rapid Processing of Uniform, Thin, Robust, and Large‐Area Garnet Solid Electrolyte by Atmospheric Plasma Spraying

AbstractAll‐solid‐state batteries (ASSBs) are rapidly moving toward commercialization as a promising high‐performance energy storage device for portable electronics and electric vehicles. One of the most challenging problems hindering the industrialization of ASSBs is the lack of technologies for cost‐effective and large‐scale manufacturing of high‐quality solid‐state electrolytes (SSEs) with about the same thickness as the polymer separators in conventional lithium‐ion batteries. Herein, atmospheric plasma spraying (APS) is adopted as a practical route to process large‐scale, uniform, and thin SSEs to conduct Li‐ions and further to manufacture ASSBs. Garnet‐type Li7La3Zr2O12 (LLZO) films with thicknesses ranging from 30 to 300 µm are successfully manufactured with direct APS technique followed with a post annealing treatment. The electrolyte reaches a high Li‐ion conductivity of 3.82 × 10−5 S cm−1 at room temperature (25 °C). Additionally, the LLZO film with a thickness of 300 µm shows a flexural strength of 157 MPa. Li/LLZO/Li and Li/LLZO/LiFePO4 cells are assembled with the films, both showing stable cycling performance. The APS method shows scalability in solid‐state electrolyte film production, and most importantly, such a process is highly compatible with the current battery industry.

Determination of wear resistance of nickel-carbide alloy coating by atmospheric plasma spray technique on 30MnB5 alloy steel used in cultivator blades

The wear that occurs during tillage in agricultural machinery shortens the material’s life and increases costs. This study investigated the microstructure and morphology of cultivator blades coated with atmospheric plasma spray (APS) process and tested under real field conditions using OM, SEM, EDX, and XRD techniques. Abrasion tests were conducted in an area of 110 hectares and under two different soil moisture conditions. Material properties were investigated using hardness and surface roughness tests. The coating process was successful both mechanically and metallurgically by applying Ni-WC ceramic-metal (cermet) powder on the surface of 30MnB5 steel substrate with APS. The oxide and carbide structures detected on the coating surface by XRD studies resulted in a 1.5 times higher coating hardness. Due to the hard carbide phases in the coating matrix, the grooves on the wear surfaces were shallow and narrow compared to the substrate sample. The surface roughness values of the coated sample were approximately two times higher than the substrate sample. Due to the microstructure and high hardness, the coated specimen experienced three times less abrasion in both humidity conditions. The APS method can be successfully applied to the machined parts of tillage machines. In the near future, the cost of agricultural production can be reduced, and the environment can benefit from this method. In conclusion, this study presents a feasible approach to improving the wear resistance of Ni-WC ceramic-metal alloy by plasma spray coating under real field conditions.

Preparation and characterization of a composite ceramic coating containing absorber LaFe12O19 by plasma spraying

A ceramic coating with both heat-resistant and electromagnetic (EM) wave absorption performances is prepared by the atmospheric plasma spraying (APS) method. The spraying powder is a composite material mainly containing LaFeO3 and La(Mg/Fe)Al11O19 without EM absorption ability. During APS procedure, a new phase of LaFe12O19 is fabricated by the chemical reaction between Fe2O3 and LaFeO3 at extremely high temperatures. The ceramic coating exhibits larger saturation magnetization (Ms) and higher EM absorption performance than that of the unsprayed sample. The coating Ms is 31 emu/g, and the optimal reflection loss is −39.30 dB at 3.5–5.2 GHz with 4.5 mm thickness. The ceramic coating with both heat-resistant and EM absorption properties is a potential application prospect material in the military industry.

Based on energy dissipation investigation of preparation and toughening mechanism of continuous transition coating

The plasticity and toughness of metals can absorb a large amount of energy. In this study, we focused on the preparation of the continuous transition coating of yttria-stabilized zirconia (YSZ) and CoNiCrAlY via the atmospheric plasma spraying (APS) method. The external force produced by Vickers hardness initiated the growth of cracks. Thus, the energy dissipation of the coatings was studied. The results confirmed that the continuous transition structure exhibits a hardness gradient change and excellent energy dissipation. The results indicated that the hardness curve of the continuous transition coating with slope kCTC = 5.728 compared to the double-layer coating curves with slope kDLC = 18.75 can alleviate the hardness differences between metals and ceramics. In contrast, CoNiCrAlY in the continuous transition zone dissipated energy through deformation, avoiding the failure of the coating caused by the large-scale fracture of the 8YSZ splats. Its energy dissipation increased with the gradient of the metal content in the continuous transition zone in the following order: ΔJsa=0J < ΔJsb=6.0072×10−9J<ΔJsc=7.3778×10−9J.

Microstructure and water corrosion behavior of (Lu0.2Yb0.2Er0.2Tm0.2Sc0.2)2Si2O7 high-entropy rare-earth disilicate coating for SiC coated C/C composites

In order to make carbon/carbon composites suitable for application in gas turbine engine, it is necessary to develop environmental barrier coatings (EBCs) to protect them from reacting with water vapor. In our previous work, a novel high-entropy rare-earth disilicate (Lu0.2Yb0.2Er0.2Tm0.2Sc0.2)2Si2O7 ((5RE0.2)2Si2O7) has been developed and verified as a promising candidate for EBCs. In this work, the (5RE0.2)2Si2O7 coating was synthesized on the surface of SiC coated C/C composites by supersonic atmospheric plasma spraying method. The protective performance and mechanism of this coating under high temperature water vapor environment was explored in detail. Results showed that the weight change of the sample coated with (5RE0.2)2Si2O7 was only 0.2% after corrosion for 100 h at 1500 ºC, which proved that (5RE0.2)2Si2O7 coating could significantly improve the resistance of C/C composites against water vapor corrosion. This work may provide theoretical basis for the design and application of high-entropy rare-earth silicates as EBCs.

Plasma sprayed graphene/carbon nanotube reinforced lanthanum-cerate hybrid composite coating

Lanthanum cerate (LC: La2Ce2O7) is a potential material for thermal barrier coating, whose improved toughness is a crucial necessity for the pathway of its industrialization. Herein, we demonstrated a promising approach to develop graphene/carbon nanotube hybrid composite coating using a large throughput and atmospheric plasma spraying method. Graphene nanoplatelets (GNP: 1 wt %) and carbon nanotube (CNT: 0.5 wt %) reinforced lanthanum cerate (LCGC) hybrid composite coatings were deposited on the Inconel substrate. Addition of 1 wt % GNP and 0.5 wt % CNT in LC matrix has significantly increased its relative density, hardness, and elastic modulus up to 97.2%, 2–3 folds, 3–4 folds, respectively. An impressive improvement of indentation toughness (8.04 ± 0.2 MPa m0.5) was observed on LCGC coating, which is ∼8 times higher comparing the LC coating. The toughening was attributed to the factors: such as the distribution of GNPs and CNTs in the LC matrix, synergistic toughening offered by the GNPs and CNTs; (i) GNP/CNT pull-out, (ii) crack bridging and arresting, (iii) splat sandwiching, mechanical interlocking, etc. Finally, this improved toughness offered an exceptional thermal shock performance up to 1721 cycles at 1800 °C, without any major failure on the coating. Therefore, the GNP and CNT-reinforced LC hybrid composite coating can be recommended to open a path for turbine industries.